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One of the top ten spinning mills in China, Texhong Group has grown steadily since its establishment in 1997, building a reputation for high value-added products in challenging market sectors such as core-spun yarns, as well as grey fabrics and fashion materials. The group’s strong quality ethic is the basis for its progress in the production of yarns for bleached fabric, where defect-free standards are absolutely critical. Here, the unique USTER ‘dual control’ approach to removing cotton contamination at both blowroom and winding machine has delivered remarkable results.
Texhong’s ambition in yarns for bleaching are underpinned by its continuing successes over the past 20 years. The group operates 3.2 million spindles – including 1.25 million in Vietnam – and 10,000 weaving machines, making it one of China’s largest and fastestgrowing textile enterprises. The depth of Texhong’s quality commitment is shown by the fact that it has five fully-equipped USTER laboratories for fiber and yarn testing. Equipment includes USTER? HVI1000 and USTER? AFIS PRO 2 for fiber tests, USTER? TESTER 5 and 6, USTER? TENSORAPID 4 and TENSOJET 4 for yarn tests, and USTER? CLASSIMAT 5 for yarn classification.
Raw material challenges
Accepted industry standards to define “contamination-free” fabrics stipulate 20 foreign fiber defects （FD） per 20 kilograms of fabric. Texhong’s results initially found 30 to 40 defects for this weight – clearly an unacceptable level, calling for an urgent remedy.
Purchasing better-quality raw cotton would seem to be the simplest solution, but the sheer volume of Texhong’s requirements means that there will inevitably need to be a mix of incoming cottons from Australia, the USA and local Chinese growers. Most of Texhong’s Chinese cotton supplies come from the Xinjiang region, which is both the largest and best-quality source in the country. Even so, Xinjiang cotton is high in contamination – especially the filmy plastic pieces cause headaches to spinners.
The next obvious solution to reducing contamination was 100% control of production by yarn clearing in the winding room – an existing option in Texhong’s yarn production processes, but not a satisfying answer to the foreign matter problem： it would lead to excessive levels of cuts at the clearers, creating too much waste and reducing efficiency, while the number of splices would ultimately damage fabric quality.
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